Electric vehicle powertrain controller

Abstract

A powertrain controller for an electric vehicle (EV) includes a compressor controller configured to regulate three-phases of electrical current supplied by a vehicle battery of the EV or an electric motor of the EV to an electrically-actuated compressor; and a load bank controller configured to regulate a fourth-phase of electrical current provided by the vehicle battery or the electric motor of the EV to a resistive load bank, such that the compressor controller and the load bank controller are integrated into a common control system.

What is claimed is: 
     
         1 . A powertrain controller for an electric vehicle (EV), comprising:
 a compressor controller configured to regulate three-phases of electrical current supplied by a vehicle battery of the EV or an electric motor of the EV to an electrically-actuated compressor; and   a load bank controller configured to regulate a fourth-phase of electrical current provided by the vehicle battery or the electric motor of the EV to a resistive load bank, wherein the compressor controller and the load bank controller are integrated into a common control system.   
     
     
         2 . The powertrain controller recited in  claim 1 , wherein the compressor controller controls a three-phase motor controller and the load bank controller controls a DC chopper circuit. 
     
     
         3 . The powertrain controller recited in  claim 2 , wherein the DC chopper circuit and the three-phase motor controller are implemented with six switches. 
     
     
         4 . The powertrain controller recited in  claim 1 , further comprising electrical connections from the powertrain controller to the resistive load bank. 
     
     
         5 . The powertrain controller recited in  claim 1 , wherein the compressor controller and the load bank controller are both within a powertrain controller housing. 
     
     
         6 . A powertrain controller for an electric vehicle (EV), comprising:
 a compressor controller, configured to electrically couple with an electrically-actuated compressor, that regulates electrical current supplied by a vehicle battery of the EV or an electric motor of the EV to the electrically-actuated compressor; and   a load bank controller configured to regulate electrical current provided by the vehicle battery or the electric motor of the EV to a resistive load bank, wherein the compressor controller and the load bank controller are both within a powertrain controller housing.   
     
     
         7 . The powertrain controller recited in  claim 6 , wherein the compressor controller controls a three-phase motor controller and the load bank controller controls a DC chopper circuit. 
     
     
         8 . The powertrain controller recited in  claim 7 , wherein the DC chopper circuit and the three-phase motor controller are implemented with at least six switches. 
     
     
         9 . The powertrain controller recited in  claim 6 , further comprising electrical connections from the powertrain controller to the resistive load bank. 
     
     
         10 . A powertrain controller for an electric vehicle (EV), comprising:
 an electrically-actuated compressor electrically connected to a control system of the powertrain controller;   a resistive load bank, including a plurality of resistors electrically connected together, that is electrically connected to the control system of the powertrain controller; and   a resistor housing that receives the resistive load bank and is in fluid communication with the compressor portion of the electrically-actuated compressor that cools the resistors,   wherein the control system is configured to receive electrical current from a vehicle battery or an electric motor used by the EV for propulsion and provide three-phase electrical current to the electrically-actuated compressor and a fourth-phase of electrical current to the resistive load bank.   
     
     
         11 . The powertrain controller recited in  claim 10 , wherein the control system includes a three-phase motor controller and a DC chopper circuit. 
     
     
         12 . The powertrain controller recited in  claim 11 , wherein the DC chopper circuit and the three-phase motor controller are implemented with at least six switches. 
     
     
         13 . The powertrain controller recited in  claim 10 , further comprising electrical connections from the powertrain controller to the resistive load bank and the electrically-actuated compressor. 
     
     
         14 . A powertrain controller for an electric vehicle (EV), comprising:
 a compressor controller configured to regulate three-phase alternating current (AC) electrical current to an electrically-actuated compressor; and   a load bank controller including a DC chopper circuit configured to regulate a fourth-phase of electrical current provided to a resistive load bank, wherein the compressor controller and the load bank controller are integrated into a common enclosure and share at least some electrical components.